US20110259715A1 - Automatic delivery system for continuous batch order processing - Google Patents
Automatic delivery system for continuous batch order processing Download PDFInfo
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- US20110259715A1 US20110259715A1 US12/766,620 US76662010A US2011259715A1 US 20110259715 A1 US20110259715 A1 US 20110259715A1 US 76662010 A US76662010 A US 76662010A US 2011259715 A1 US2011259715 A1 US 2011259715A1
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- rollers
- container
- powered
- delivery system
- station
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
- B65G1/00—Storing articles, individually or in orderly arrangement, in warehouses or magazines
- B65G1/02—Storage devices
- B65G1/04—Storage devices mechanical
- B65G1/137—Storage devices mechanical with arrangements or automatic control means for selecting which articles are to be removed
- B65G1/1373—Storage devices mechanical with arrangements or automatic control means for selecting which articles are to be removed for fulfilling orders in warehouses
- B65G1/1378—Storage devices mechanical with arrangements or automatic control means for selecting which articles are to be removed for fulfilling orders in warehouses the orders being assembled on fixed commissioning areas remote from the storage areas
Definitions
- the present disclosure relates to automatic delivery systems for moving goods from an inventory site to a packaging site and away from the packaging site.
- Automated delivery systems commonly use conveyor systems to move empty or incomplete containers to fill sites and subsequently to move completed containers for shipment.
- Completed containers include one of more items, ordered for example via the Internet, and can be subsequently delivered by a shipping company to individuals or companies.
- Delivery systems can also include a computer to control the positioning of goods or movement of goods within a warehousing system to facilitate loading the various containers for delivery.
- the use of one or more carousels having a plurality of individual products or goods to move the products closer to a loading station for an operator or automated loader to insert the products into a container are also known.
- an automatic delivery system includes a conveyor including rollers arranged in parallel with each other defining a common spacing between any sequential ones of the rollers.
- the rollers are divisible into at least two groups, each of the at least two groups including a loading station at one end of the rollers.
- Each of the at least two groups have a station positioning device including at least one extension rod extending through and displaceable within the spacing between sequential ones of the rollers. The station positioning device operates to displace a container received on the rollers into and out of the loading station.
- an automatic delivery system includes a conveyor including powered first rollers arranged in parallel with each other defining a spacing between sequential ones of the first powered rollers.
- Fixed second rollers are each connected to and coaxially aligned with individual ones of the first powered rollers and sequentially separated by the spacing of the first powered rollers.
- the second rollers are divisible into at least two groups, each of the at least two groups defining a loading station.
- Each of the loading stations has a station positioning device including at least one extension rod extending through and horizontally displaceable within the spacing between sequential ones of the powered first and fixed second rollers. The station positioning device operates to displace a container received on the powered first rollers into and out of the loading station.
- an automatic delivery system includes a conveyor having powered first rollers arranged in parallel with each other defining a common spacing between sequential ones of the first powered rollers.
- Fixed second rollers are each connected to and coaxially aligned with individual ones of the first powered rollers and sequentially separated by the spacing between the first powered rollers.
- the second rollers are divisible into at least two groups, each of the at least two groups defining a loading station.
- Each of the loading stations has a station positioning device including at least one extension rod extending through and horizontally displaceable within the spacing between first sequential ones of the powered first and fixed second rollers. The station positioning device operates to displace a container received on the powered first rollers into and out of the loading station.
- a stop device is positioned between and is extended upwardly and retracted downwardly through the spacing between second sequential ones of the powered first and fixed second rollers.
- the stop device extended upwardly stops the container for subsequent displacement by the station delivery device, and extended downwardly permits free passage of the container on the first powered rollers.
- an automatic delivery system includes a conveyor including rollers arranged in parallel with each other defining a common spacing between any sequential ones of the rollers.
- the rollers are divisible into at least two groups, each of the at least two groups including a loading station at one end of the rollers.
- Each of the at least two groups have a station positioning device including at least one extension rod extending through and displaceable within the spacing between sequential ones of the rollers.
- the station positioning device operates to displace a container received on the rollers into and out of the loading station.
- At least one carousel includes a plurality of component containing carousel bins.
- a selected one of the plurality of carousel bins is movable to a pick location for removal of at least one item to be placed in the container positioned in the loading station.
- a computer controls the station positioning device and the carousel. The computer has access to data for components to be inserted into the container at the loading station of each group and operates to select a next pick location to minimize movement of the at least one carousel.
- FIG. 1 is a top plan view of an automatic delivery system for moving goods of the present disclosure
- FIG. 2 is a top plan view of a loading station of the automatic delivery system of FIG. 1 ;
- FIG. 3 is a top plan view of area 3 of the loading station of FIG. 2 ;
- FIG. 4 is a front elevational view of the loading station of FIG. 2 ;
- FIG. 5 is a front elevational view of area 5 of FIG. 4 ;
- FIG. 6 is an end elevational view at section 6 of FIG. 2 ;
- FIG. 7 is an end elevational view taken at section 7 of FIG. 2 ;
- FIG. 8 is a partial cross sectional view taken at section 8 of FIG. 3 ;
- FIG. 9 is a top plan view similar to FIG. 1 showing further details of the automatic delivery system
- FIG. 10 is a front elevational view of a put-to-light section of the loading station.
- FIG. 11 is a right front perspective view of the automatic delivery system.
- Example embodiments are provided so that this disclosure will be thorough, and will fully convey the scope to those who are skilled in the art. Numerous specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms and that neither should be construed to limit the scope of the disclosure. In some example embodiments, well-known processes, well-known device structures, and well-known technologies are not described in detail.
- first, second, third, etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as “first,” “second,” and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example embodiments.
- Spatially relative terms such as “inner,” “outer,” “beneath,” “below,” “lower,” “above,” “upper,” and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. Spatially relative terms may be intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, the example term “below” can encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.
- a delivery system 10 includes a loading station 12 which receives incomplete containers 14 via a container feed conveyor 16 . From the container feed conveyor 16 , the incomplete containers 14 change from a first feed direction “A” to a second feed direction “B” for travel on a container receiving station 18 . The incomplete containers 14 travel along the container receiving station 18 until they reach a container code reading device 20 which provides input data to the delivery system 10 identifying the size of incomplete container 14 and the predetermined contents to be loaded at loading station 12 .
- a complete container 22 (having all required content items) is discharged from loading station 12 onto a complete container transport conveyor 24 .
- the complete container 22 travels in a container transport direction “C” as it leaves loading station 12 and can change to a complete container transport direction “D” as it transits the complete container transport conveyor 24 .
- Individual products that are to be loaded into the containers 14 can be provided on at least one and according to several embodiments multiple carousels such as first, second, and third carousels 26 , 28 , 30 .
- the first, second, and third carousels 26 , 28 , 30 rotate to provide each of a first, second, and third pick location 32 , 34 , 36 which is within reach of an operator located at loading station 12 .
- the configuration of the various conveyers shown in FIG. 1 is one example of an embodiment for delivery system 10 .
- the various conveyors can also be reconfigured from those shown such that infeed and outfeed of the various containers can be in opposite directions or in additional directions depending upon the available space of the facility within which delivery system 10 is constructed.
- loading station 12 further includes a container entry portion 38 which receives containers 14 in a container entry direction “E” as they are unloaded from container receiving station 18 . From container entry portion 38 , the incomplete containers 14 move onto a container fill station 40 as individual units in the container entry direction “E” or the incomplete containers 14 can be moved in the container transport direction “C” onto a container load/discharge portion 42 .
- Container load/discharge portion 42 includes at least one and according to several embodiments a plurality of loading stations 44 identified for example as loading stations 44 a , 44 b , 44 c , 44 d , 44 e , 44 f , 44 g , and 44 h .
- the number of loading stations 44 can vary at the discretion of the designer and eight of the loading stations 44 are shown in the exemplary embodiment representing an example number of loading stations capable of being controlled by a single operator/loader.
- Each of the loading stations 44 is fed by a conveyor 45 having a load/discharge section 46 and an infeed/discharge section 48 .
- Incomplete containers 14 moving in the container transport direction “C” along container load/discharge portion 42 are individually moved until they reach a desired one of the loading stations 44 at which time they are stopped and then displaced in the container entry direction “E” into the appropriate loading station 44 .
- containers within the individual loading stations 44 move the complete containers in the complete container discharge direction “F” from the various loading stations 44 into the infeed/discharge section 48 which is powered to move either incomplete containers 14 or complete containers 22 in the container transport direction “C”.
- Container fill station 40 having a container 14 a shown is similarly received and filled in container fill station 40 and then moved in the complete container discharge direction “F” to align the now complete container 22 with the infeed/discharge section 48 for discharge in the container transport direction “C”.
- loading station 12 further includes a directing bar 50 which realigns the individual incomplete containers 14 moving in the second feed direction “B” along container receiving station 18 to align the incomplete containers 14 to be subsequently stopped by a stop member 52 .
- a directing bar 50 which realigns the individual incomplete containers 14 moving in the second feed direction “B” along container receiving station 18 to align the incomplete containers 14 to be subsequently stopped by a stop member 52 .
- the incomplete container 14 contacts stop member 52 the incomplete container is moved in the container entry direction “E” using an incomplete container rod-less cylinder 54 which includes a first pusher member 56 movable between the positions indicated by first pusher member 56 and first pusher member 56 ′.
- the term “rod-less cylinder” also broadly includes linear actuator, magnetic cylinder and similar linear movement devices.
- First pusher member 56 displaces the incomplete container 14 onto an entry conveyor system 58 having a plurality of powered conveyor rollers 60 sequentially spaced from each other by a common spacing “S 1 ”.
- Conveyor rollers 60 are individually rotated by a rotating power shaft 62 which is driven by a motor (not shown). Incomplete containers 14 delivered onto conveyor rollers 60 continue to be directed by stop member 52 until the incomplete container 14 reaches a container redirecting section 64 of container entry portion 38 .
- a second stop device 66 is positioned between conveyor rollers 60 a and 60 b .
- Second stop device 66 can be raised or lowered such that an incomplete container 14 received in container redirecting section 64 can be passed directly through into container fill station 40 , or stopped by second stop device 66 in a raised position for subsequent redirecting of the incomplete container 14 onto container load/discharge portion 42 .
- a plurality of the conveyor rollers 60 are sequentially positioned at the container fill station 40 to define a container first loading section 68 .
- An incomplete container such as incomplete container 14 a received in the container fill station 40 abuts against a second stop member 70 which is fixed in position and coaxially aligned with stop member 52 until the incomplete container 14 a contacts a fixed stop member 72 at the position of incomplete container 14 a shown.
- a direction of rotation of each of the conveyor rollers 60 of container first loading section 68 and container redirecting section 64 can be reversed to move the now complete container in the complete container discharge direction “F” until the complete container contacts a raised third stop device 74 .
- Third stop device 74 is positioned between conveyor rollers 60 c and 60 d , respectively. Similar to second stop device 66 , third stop device 74 can be raised or lowered to be above or below the elevation of conveyor rollers 60 in container redirecting section 64 . For example, third stop device 74 is positioned in the lowered position to permit incomplete container 14 a to reach the container fill station 40 .
- a third pusher member 76 which is coaxially aligned with each of stop member 52 and second stop member 70 in a first operating position, is moved from the position shown as third pusher member 76 to the position shown as third pusher member 76 ′.
- Each of the loading stations 44 includes a station positioning device 78 represented by the various station positioning devices 78 , 78 a , 78 b , and 78 c .
- Each station positioning device 78 includes a first pusher/alignment member 80 and an oppositely positioned second pusher/alignment member 82 .
- the first and second pusher/alignment members 80 , 82 are movable from the positions shown in the container entry direction “E” to displace an incomplete container 14 into one of the loading stations 44 .
- Each of the station positioning devices 78 therefore includes a rod-less cylinder 84 having a slidably displaced carriage member 86 with the first and second pusher/alignment members 80 , 82 connected thereto.
- the carriage member 86 is movable from the position shown as carriage member 86 to the position shown as carriage member 86 ′ by powered operation such as by using a pressurized air system for displacement.
- a first stop device 88 which is similar to second and third stop devices 66 , 74 in operation, will be raised to provide a stop point for the incomplete container 14 , therefore positioning the incomplete container 14 between first and second pusher/alignment members 80 , 82 .
- First stop device 88 is actuated using a stop actuator 90 which is connected to structure supporting loading station 12 .
- First stop device 88 is coaxially aligned with an alignment guide 92 , commonly provided in each of the loading stations 44 . The incomplete container 14 moving into loading station 44 a therefore slides with respect to first stop device 88 until it slidably contacts alignment guide 92 , which provides a consistent location for any of the incomplete containers 14 received in loading station 44 a or any of the other loading stations.
- the first and second pusher/alignment members 80 , 82 are retained in the displaced position (i.e., as shown in loading station 44 c ) as the container is filled.
- the carriage member 86 (shown as carriage member 86 ′ in loading station 44 c ) is commanded to move in the complete container discharge direction “F”, whereby second pusher/alignment member 82 ′ provides a motive force for displacing the now complete container 22 from the loading station 44 c and back onto infeed/discharge section 48 for discharge from loading station 12 .
- In feed/discharge section 48 further includes an individual stop device (such as fourth, fifth, sixth stop devices 94 , 96 , 98 ) associated with each of the individual loading stations (i.e., loading stations 44 b , 44 c , 44 d ) to stop the travel of an incomplete container 14 traveling in the container transport direction “C” on infeed/discharge section 48 for subsequent delivery into one of the various loading stations 44 .
- an individual stop device such as fourth, fifth, sixth stop devices 94 , 96 , 98 ) associated with each of the individual loading stations (i.e., loading stations 44 b , 44 c , 44 d ) to stop the travel of an incomplete container 14 traveling in the container transport direction “C” on infeed/discharge section 48 for subsequent delivery into one of the various loading stations 44 .
- Each of the stop devices operate in a similar manner using a similar stop actuator, such as stop actuator 90 .
- loading station 12 can further include a plurality of support stanchions 100 (such as support stanchions 100 a , 100 b , 100 c , 100 d ) generally oriented in a vertical configuration and connected to a support surface 102 , such as a substantially planar floor surface.
- Container entry portion 38 further includes a second stop device actuator 104 operable to move second stop device 66 upwardly or downwardly as previously described herein.
- a plurality of substantially equally spaced, partially fixed conveyor rollers 106 are arranged in parallel and rotatably connected to a roller support structure 107 .
- Roller support structure 107 is subsequently connected to a support beam 108 , which is connected to and supported by the various support stanchions 100 .
- the height of the conveyor rollers 106 with respect to support surface 102 can be varied, if desired, by using adjustable members in support stanchions 100 to accommodate a plurality of container sizes.
- each of the conveyor rollers 60 of container entry portion 38 are arranged in parallel with each other such that a planar surface 110 , defined by the upper surface 112 of each of the conveyor rollers 60 , is oriented coplanar to the same planar surface 110 defined by the upper surfaces 114 of each of the conveyor rollers 106 .
- second stop device 66 can be lowered to a position below planar surface 110 to permit free transportation of the containers and can be raised to the position shown at second stop device 66 ′, positioned above the planar surface 110 , by actuation of second stop device actuator 104 .
- the first stop device 88 and similar stop devices are movable by an extendable shaft 116 connected to a stop device arm 118 .
- Stop actuator 90 displaces the extendable shaft 116 , thereby moving both stop device arm 118 and first stop device 88 either upwardly or downwardly.
- Each of the stop devices such as first stop device 88 , is positioned between successive ones of conveyor rollers 106 , such as between conveyor rollers 106 a , 106 b .
- Each of the various pusher members such as second pusher/alignment member 82 a , includes a pusher extension rod 120 connected to a pusher actuator, such as pusher actuator 122 .
- Pusher actuator 122 is connected to support beam 108 .
- the pusher extension rod 120 similar to stop device arm 118 , is positioned between successive ones of the conveyor rollers 106 , such as between conveyor rollers 106 c , 106 d.
- each of the conveyor rollers 106 is divisible into a fixed roller 124 and a powered roller 126 .
- Fixed roller 124 is not axially rotatable and is therefore fixed in position to receive and temporarily support the individual incomplete or complete containers.
- a bearing assembly 128 separates fixed roller 124 from powered roller 126 , permitting powered roller 126 to axially rotate.
- a drive belt 130 or any similar drive or motive device is provided for each of the individual powered rollers 126 , which if in belt form is rotatably connected to a drive shaft 131 powered by a motor (not shown).
- a guide member 132 can be provided at loading station 12 , which can provide additional support for taller ones of the containers (i.e., container 14 c ).
- Guide member 132 is supported by a plurality of guide member support arms 134 , which can be connected to roller support structure 107 .
- fixed rollers 124 can also be replaced by any fixed or stationary surface.
- container receiving station 18 includes a plurality of powered rollers 135 directing incomplete containers 14 toward stop member 52 . Similar to powered rollers 126 shown and described with respect to FIG. 6 , each of the conveyor rollers 60 of container entry portion 38 is similarly rotated using a drive belt 136 connected to a pulley 138 , which is rotated by a drive shaft 140 .
- a direction of rotation R 1 of each of the conveyor rollers 60 used to direct the container in the container entry direction “E” onto container first loading section 68 and container redirection section 64 can be reversed to a direction of rotation R 2 to move the now complete container in the complete container discharge direction “F” until the complete container contacts raised third stop device 74 .
- Second stop device 66 is lowered during this event.
- the one or more drive belts 136 is/are received in a drive slot 142 created in each of the conveyor rollers 60 .
- Drive slot 142 is provided to maintain alignment of pulley 138 and also to keep each drive belt 136 positioned below upper surface 112 , thereby not interfering with the passage of the containers with respect to upper surface 112 .
- a carriage member 143 is slidably disposed on incomplete container rod-less cylinder 54 to slidably displace pusher member 56 .
- a third stop device actuator 144 is provided to upwardly and downwardly move third stop device 74 .
- a pusher member actuator 145 connected to a pusher member rod 147 is actuated to move third pusher member 76 .
- An actuator controller 146 can be provided to control the flow of, for example, pressurized air to any of the stop actuators 90 , second stop device actuator 104 , pusher actuators 122 , stop device actuator 144 , and/or pusher member actuator 145 .
- a system controller 148 is provided, which communicates with each of the drive motors, stop actuators, and pusher actuators, to direct operation of these items in the sequential order necessary for moving the containers about loading station 12 .
- System controller 148 therefore may contain hardware and electronic controls directed to the sequential operation of loading station 12 , including operation of the various motors for driving the conveyor rollers and code reading devices.
- a programmable logic device and/or one or more computers, herein collectively defined as a computer 150 is also provided with delivery system 10 , which can be incorporated within system controller 148 .
- Computer 150 can be programmed with or connected to other computers or databases to request information, such as the type and quantity of components to be inserted into each container, the station or stations at which individual containers are directed to, the timing of the entry and exit of the various containers from the system, the timing of operation of the various stop devices and pusher members, and can receive and implement commands for operation of system controller 148 from a programmer and/or an operator.
- Loading station 12 can further include a support frame 152 adapted to support the features of container entry portion 38 .
- the plurality of conveyor rollers 60 is rotatably disposed with respect to first and second mount brackets 156 , 158 , which themselves are fixedly connected to first and second mount plates 160 a , 160 b .
- An exemplary one of the rod-less cylinders is shown in greater detail having third pusher member 76 connected to a carriage member 159 which is slidably disposed on rod-less cylinder 161 .
- rod-less cylinder 161 can further be fixedly connected to the first and second mount plates 160 a , 160 b .
- Rod-less cylinder 161 includes a slide track 162 which provides for sliding motion of carriage member 159 and thereby third pusher member 76 between the first and second mount plates 160 a , 160 b .
- Third pusher member 76 can slide between the position shown as third pusher member 76 to the position shown as third pusher member 76 ′ in each of the container transport direction “C” and pusher return direction “H”.
- delivery system 10 includes a container reading station 164 which includes container code reading device 20 which is capable of reading a automatic identification 166 attached to each of the incomplete containers 14 as they arrive at container reading station 164 .
- container code reading device 20 which is capable of reading a automatic identification 166 attached to each of the incomplete containers 14 as they arrive at container reading station 164 .
- This data indicating the individual type of incomplete container 14 and its entrance into the system is then transmitted to computer 150 , shown and described in reference to FIG. 7 .
- a complete container code reading device 168 can also be provided at a discharge end of loading station 12 which is operable to read an automatic identification 166 such as a bar code or RF tag, RFID reader, or similar means of container identification from the now complete container 22 as it leaves loading station 12 .
- This information is also forwarded to computer 150 which confirms that complete container 22 has exited from loading station 12 .
- Each of the first, second, and third carousels 26 , 28 , 30 can include a motorized track 170 about which a plurality of carousel bins 172 are connected and rotate with respect to a carousel rotational direction “J” which can be either a clockwise or counterclockwise direction of rotation.
- Delivery system 10 is provided with the information relating the individual components 175 which are provided in the carousel bins 172 with this information further programmed into computer 150 .
- Delivery system 10 is, therefore, programmed to provide the individual carousel bins 172 necessary to fill individual ones of the containers 14 with at least one item 175 by an operator positioned within a fill area 174 by positioning the various carousel bins 172 at individual ones of the first, second, or third pick locations 32 , 34 , 36 , which are proximately located to fill area 174 .
- a put to light system 176 provides a plurality of push button display units 178 , shown for example as push button display units 178 a , 178 b , 178 c , positioned in individual ones of loading stations 44 a , 44 b , 44 c .
- Each of the push button display units 178 is connected to a mounting channel 180 which can be connected to structure of loading station 12 .
- Each of the push button display units 178 includes a data read out screen 182 , which provides for the operator component information such as an identification number, and a quantity of a unique component required to fill/complete an individual container or two or more containers, and other information related to completing the container, such as loading station 44 a .
- a plurality of data entry buttons 184 is provided with each of the push button display units 178 for the operator to enter data, such as the quantify of the part or parts actually loaded into the container. Included with data entry buttons 184 is a container complete button 184 a , which the operator presses to indicate to delivery system 10 that the container positioned at the appropriate loading station has been completed. This information presented by and input into push button display unit 178 is also transmitted to computer 150 , shown and described with reference to FIG. 7 .
- operation of loading station 12 can be as follows. An incomplete container 14 received at stop member 52 is pushed by operation of first pusher member 56 in the second feed direction “B” onto conveyor rollers 60 of container entry portion 38 . If the incomplete container 14 is to be transferred to container fill station 40 , both second and third stop devices 66 , 74 are positioned in a lowered position below the upper plane defined by conveyor rollers 60 . Conveyor rollers are rotated to move incomplete container 14 in the second feed direction “B” until incomplete container 14 contacts fixed stop member 72 , at which time the container is available for filling.
- Second stop device 66 is kept at the lowered position and third stop device 74 is raised to stop complete container 22 such that subsequent operation of pusher member 76 in the container transport direction “C” pushes the container onto power rotated rollers 126 for subsequent discharge from loading station 12 .
- third stop device 74 is positioned at the lowered position and second stop device 66 is raised to stop the container(s) for subsequent movement by pusher member 76 onto power rotated rollers 126 .
- the incomplete container is moved in the container transport direction “C” on power rotated rollers 126 until reaching the predetermined loading station 44 .
- one of the first, fourth, fifth, or later stop devices 88 , 94 , 96 and the like is raised.
- the appropriate first and second pusher/alignment members 80 , 82 (or 80 ′, 82 ′ or the like) is moved in the container entry direction “E” until the incomplete container is positioned on fixed rollers 124 of infeed/discharge section 48 , where the container is loaded.
- the operator receives the appropriate loading information on the pushbutton display unit 178 at the loading station, and notifies the system when all the tasks (fill items) related to the container are complete (or if all the available parts in the carousel have been loaded) by data entry into pushbutton display unit 178 .
- This complete signal notifies the delivery system that complete container 22 should be moved in the complete container discharge direction “F” by actuation of first and second pusher/alignment members 80 , 82 (or 80 ′, 82 ′ or the like) until the complete container is moved onto power rotated rollers 126 of load/discharge section 46 .
- first, fourth, fifth, and later stop devices 88 , 94 , 96 and the like are sequentially lowered to permit the complete container to exit load/discharge section 46 in the container transport direction “C”.
- the incomplete or complete status of each of the containers on loading station 12 is tracked by delivery system 10 , as well as the position of each container. Additional sensor devices such as UPC code readers or similar identification devices noted herein can be used at each loading station and/or at each position of the first, fourth, fifth, and later stop devices 88 , 94 , 96 and the like if desired.
- An automatic delivery system 10 of the present disclosure can therefore include conveyor 45 having rollers 106 arranged in parallel with each other defining a common spacing “S 2 ” between any sequential ones of the rollers 106 . Spacing “S 2 ” can be equal to or different from spacing “S 1 ” used for rollers 60 of container entry portion 38 .
- the conveyor rollers 106 are divisible into at least two groups defined as load/discharge section 46 and infeed/discharge section 48 , each of the at least two groups including a loading station 44 at one end of the conveyor rollers 106 .
- Each of the at least two groups having a station positioning device 78 including at least one extension rod 120 extending through and displaceable within the spacing “S 2 ” between two sequential ones (for example 106 c , 106 d ) of the rollers 106 , the station positioning device 78 operating to displace a container 14 received on the rollers 106 into and out of the loading station 44 .
- automatic delivery system 10 includes conveyor 45 having first powered rollers 126 arranged in parallel with each other defining a spacing “S 2 ” between sequential ones of the powered rollers 126 .
- Second fixed rollers 124 are each connected to and coaxially aligned with individual ones of the powered rollers 126 and sequentially separated by the spacing “S 2 ” of the first powered rollers 126 .
- the second fixed rollers 124 are divisible into at least two groups, each of the at least two groups defining a loading station 44 such as loading stations 44 a , 44 b , 44 c , and the like.
- Each of the loading stations 44 have a station positioning device 78 including at least one extension rod 120 extending through and horizontally displaceable within the spacing “S 2 ” between two sequential ones of the powered first and fixed second rollers (for example between conveyor rollers 106 c , 106 d ), the station positioning device 78 operating to displace a container 14 received on the first powered rollers 126 into and out of the loading station ( 44 a , 44 b , 44 c , and the like).
- rollers 60 of container entry portion 38 and the fixed rollers 124 can be replaced with individual fixed members or by fixed surfaces having access for operation of the various pusher members and stop devices created therethrough.
- Other types of conveyors such as fixed or belt conveyors can also be used in place of rollers 60 of container entry portion 38 and the fixed rollers 124 .
- a stop device (such as first stop device 88 ) is positioned between and extended upwardly and retracted downwardly through the spacing “S 2 ” between second sequential ones ( 106 a , 106 b ) of the first powered rollers 126 and second fixed rollers 124 .
- the stop device (such as first stop device 88 ) is extended upwardly to stop the container 14 for subsequent displacement by the station positioning device 78 , and is extended downwardly to permit free passage of the container 14 on the first powered rollers 126 .
- containers 14 are scanned automatically when entering the Continuous Batch Order Processing System 10 .
- computer 150 assigns a loading station destination and then controls and tracks the routing of that container 14 to the assigned station.
- computer 150 retrieves picking data (i.e., item stock numbers and quantities) from a database or other computer having this data, calculates optimum first, second, and/or third carousel 26 , 28 , or 30 rotation direction and pick sequence, then sends rotational commands to a carousel controller to retrieve the product(s) required. Multiple ones of first, second, and third carousels 26 , 28 , 30 may spin concurrently to their next pick location. If additional container loading stations 44 are empty, incomplete containers 14 will be automatically inducted, scanned, and routed to their assigned locations until all stations 44 are occupied or there are no additional containers to induct.
- picking data i.e., item stock numbers and quantities
- computer 150 monitors the rotation of carousels 26 , 28 , 30 .
- computer 150 illuminates a pick light display adjacent to the pick position identifying the location and quantity of product (item) to pick at pick location 32 , 34 , or 36 .
- a PC display adjacent to the carousel 26 , 28 , or 30 shows a graphical representation of the pick location on a carousel shelf, a picture of the item to pick (if available), a quantity to pick, an item description, and any additional information applicable to the required task.
- one or more put-to-light displays located in front of each container 14 at the loading stations 44 will display the quantity of product (item or items) to put into each adjacent container 14 .
- the operator depresses the task complete button at the appropriate container loading station 44 pushbutton display unit 178 to signal completion of the put (task) for the product picked.
- computer 150 will display ‘DONE’ on the put light at the pushbutton display unit 178 of the particular loading station 44 , automatically transfer the completed container 22 back to the infeed/discharge conveyor 48 and automatically induct the next incomplete container 14 into the now empty loading station 44 .
- the computer 150 recalculates required picks and optimum carousel rotational sequence for all containers in the batch.
Abstract
Description
- The present disclosure relates to automatic delivery systems for moving goods from an inventory site to a packaging site and away from the packaging site.
- This section provides background information related to the present disclosure which is not necessarily prior art.
- Automated delivery systems commonly use conveyor systems to move empty or incomplete containers to fill sites and subsequently to move completed containers for shipment. Completed containers include one of more items, ordered for example via the Internet, and can be subsequently delivered by a shipping company to individuals or companies. Delivery systems can also include a computer to control the positioning of goods or movement of goods within a warehousing system to facilitate loading the various containers for delivery. The use of one or more carousels having a plurality of individual products or goods to move the products closer to a loading station for an operator or automated loader to insert the products into a container are also known.
- This section provides a general summary of the disclosure, and is not a comprehensive disclosure of its full scope or all of its features.
- According to several embodiments of the present disclosure, an automatic delivery system includes a conveyor including rollers arranged in parallel with each other defining a common spacing between any sequential ones of the rollers. The rollers are divisible into at least two groups, each of the at least two groups including a loading station at one end of the rollers. Each of the at least two groups have a station positioning device including at least one extension rod extending through and displaceable within the spacing between sequential ones of the rollers. The station positioning device operates to displace a container received on the rollers into and out of the loading station.
- According to further embodiments, an automatic delivery system includes a conveyor including powered first rollers arranged in parallel with each other defining a spacing between sequential ones of the first powered rollers. Fixed second rollers are each connected to and coaxially aligned with individual ones of the first powered rollers and sequentially separated by the spacing of the first powered rollers. The second rollers are divisible into at least two groups, each of the at least two groups defining a loading station. Each of the loading stations has a station positioning device including at least one extension rod extending through and horizontally displaceable within the spacing between sequential ones of the powered first and fixed second rollers. The station positioning device operates to displace a container received on the powered first rollers into and out of the loading station.
- According to additional embodiments, an automatic delivery system includes a conveyor having powered first rollers arranged in parallel with each other defining a common spacing between sequential ones of the first powered rollers. Fixed second rollers are each connected to and coaxially aligned with individual ones of the first powered rollers and sequentially separated by the spacing between the first powered rollers. The second rollers are divisible into at least two groups, each of the at least two groups defining a loading station. Each of the loading stations has a station positioning device including at least one extension rod extending through and horizontally displaceable within the spacing between first sequential ones of the powered first and fixed second rollers. The station positioning device operates to displace a container received on the powered first rollers into and out of the loading station. A stop device is positioned between and is extended upwardly and retracted downwardly through the spacing between second sequential ones of the powered first and fixed second rollers. The stop device extended upwardly stops the container for subsequent displacement by the station delivery device, and extended downwardly permits free passage of the container on the first powered rollers.
- According to still further embodiments, an automatic delivery system includes a conveyor including rollers arranged in parallel with each other defining a common spacing between any sequential ones of the rollers. The rollers are divisible into at least two groups, each of the at least two groups including a loading station at one end of the rollers. Each of the at least two groups have a station positioning device including at least one extension rod extending through and displaceable within the spacing between sequential ones of the rollers. The station positioning device operates to displace a container received on the rollers into and out of the loading station. At least one carousel includes a plurality of component containing carousel bins. A selected one of the plurality of carousel bins is movable to a pick location for removal of at least one item to be placed in the container positioned in the loading station. A computer controls the station positioning device and the carousel. The computer has access to data for components to be inserted into the container at the loading station of each group and operates to select a next pick location to minimize movement of the at least one carousel.
- Further areas of applicability will become apparent from the description provided herein. The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.
- The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure.
-
FIG. 1 is a top plan view of an automatic delivery system for moving goods of the present disclosure; -
FIG. 2 is a top plan view of a loading station of the automatic delivery system ofFIG. 1 ; -
FIG. 3 is a top plan view ofarea 3 of the loading station ofFIG. 2 ; -
FIG. 4 is a front elevational view of the loading station ofFIG. 2 ; -
FIG. 5 is a front elevational view ofarea 5 ofFIG. 4 ; -
FIG. 6 is an end elevational view atsection 6 ofFIG. 2 ; -
FIG. 7 is an end elevational view taken at section 7 ofFIG. 2 ; -
FIG. 8 is a partial cross sectional view taken at section 8 ofFIG. 3 ; -
FIG. 9 is a top plan view similar toFIG. 1 showing further details of the automatic delivery system; -
FIG. 10 is a front elevational view of a put-to-light section of the loading station; and -
FIG. 11 is a right front perspective view of the automatic delivery system. - Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings.
- Example embodiments will now be described more fully with reference to the accompanying drawings.
- Example embodiments are provided so that this disclosure will be thorough, and will fully convey the scope to those who are skilled in the art. Numerous specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms and that neither should be construed to limit the scope of the disclosure. In some example embodiments, well-known processes, well-known device structures, and well-known technologies are not described in detail.
- The terminology used herein is for the purpose of describing particular example embodiments only and is not intended to be limiting. As used herein, the singular forms “a,” “an,” and “the” may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms “comprises,” “comprising,” “including,” and “having,” are inclusive and therefore specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. It is also to be understood that additional or alternative steps may be employed.
- When an element or layer is referred to as being “on,” “engaged to,” “connected to,” or “coupled to” another element or layer, it may be directly on, engaged, connected or coupled to the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being “directly on,” “directly engaged to,” “directly connected to,” or “directly coupled to” another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., “between” versus “directly between,” “adjacent” versus “directly adjacent,” etc.). As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.
- Although the terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as “first,” “second,” and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example embodiments.
- Spatially relative terms, such as “inner,” “outer,” “beneath,” “below,” “lower,” “above,” “upper,” and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. Spatially relative terms may be intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, the example term “below” can encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.
- Referring to
FIG. 1 , adelivery system 10 includes aloading station 12 which receivesincomplete containers 14 via a container feed conveyor 16. From the container feed conveyor 16, theincomplete containers 14 change from a first feed direction “A” to a second feed direction “B” for travel on acontainer receiving station 18. Theincomplete containers 14 travel along thecontainer receiving station 18 until they reach a containercode reading device 20 which provides input data to thedelivery system 10 identifying the size ofincomplete container 14 and the predetermined contents to be loaded at loadingstation 12. - Once one or more products are loaded into
container 14, a complete container 22 (having all required content items) is discharged from loadingstation 12 onto a completecontainer transport conveyor 24. Thecomplete container 22 travels in a container transport direction “C” as it leaves loadingstation 12 and can change to a complete container transport direction “D” as it transits the completecontainer transport conveyor 24. - Individual products that are to be loaded into the
containers 14 can be provided on at least one and according to several embodiments multiple carousels such as first, second, andthird carousels third carousels third pick location station 12. The configuration of the various conveyers shown inFIG. 1 is one example of an embodiment fordelivery system 10. The various conveyors can also be reconfigured from those shown such that infeed and outfeed of the various containers can be in opposite directions or in additional directions depending upon the available space of the facility within whichdelivery system 10 is constructed. - Referring to
FIG. 2 ,loading station 12 further includes acontainer entry portion 38 which receivescontainers 14 in a container entry direction “E” as they are unloaded fromcontainer receiving station 18. Fromcontainer entry portion 38, theincomplete containers 14 move onto acontainer fill station 40 as individual units in the container entry direction “E” or theincomplete containers 14 can be moved in the container transport direction “C” onto a container load/discharge portion 42. Container load/discharge portion 42 includes at least one and according to several embodiments a plurality ofloading stations 44 identified for example as loadingstations loading stations 44 can vary at the discretion of the designer and eight of theloading stations 44 are shown in the exemplary embodiment representing an example number of loading stations capable of being controlled by a single operator/loader. Each of theloading stations 44 is fed by aconveyor 45 having a load/discharge section 46 and an infeed/discharge section 48.Incomplete containers 14 moving in the container transport direction “C” along container load/discharge portion 42 are individually moved until they reach a desired one of theloading stations 44 at which time they are stopped and then displaced in the container entry direction “E” into theappropriate loading station 44. After each of the containers are filled, devices within theindividual loading stations 44 move the complete containers in the complete container discharge direction “F” from thevarious loading stations 44 into the infeed/discharge section 48 which is powered to move eitherincomplete containers 14 orcomplete containers 22 in the container transport direction “C”.Container fill station 40 having acontainer 14 a shown is similarly received and filled incontainer fill station 40 and then moved in the complete container discharge direction “F” to align the nowcomplete container 22 with the infeed/discharge section 48 for discharge in the container transport direction “C”. - Referring to
FIG. 3 ,loading station 12 further includes a directingbar 50 which realigns the individualincomplete containers 14 moving in the second feed direction “B” alongcontainer receiving station 18 to align theincomplete containers 14 to be subsequently stopped by astop member 52. Once theincomplete container 14 contacts stopmember 52, the incomplete container is moved in the container entry direction “E” using an incomplete containerrod-less cylinder 54 which includes afirst pusher member 56 movable between the positions indicated byfirst pusher member 56 andfirst pusher member 56′. As used herein, the term “rod-less cylinder” also broadly includes linear actuator, magnetic cylinder and similar linear movement devices.First pusher member 56 displaces theincomplete container 14 onto anentry conveyor system 58 having a plurality ofpowered conveyor rollers 60 sequentially spaced from each other by a common spacing “S1”.Conveyor rollers 60 are individually rotated by arotating power shaft 62 which is driven by a motor (not shown).Incomplete containers 14 delivered ontoconveyor rollers 60 continue to be directed bystop member 52 until theincomplete container 14 reaches acontainer redirecting section 64 ofcontainer entry portion 38. - A
second stop device 66 is positioned betweenconveyor rollers Second stop device 66 can be raised or lowered such that anincomplete container 14 received incontainer redirecting section 64 can be passed directly through intocontainer fill station 40, or stopped bysecond stop device 66 in a raised position for subsequent redirecting of theincomplete container 14 onto container load/discharge portion 42. A plurality of theconveyor rollers 60 are sequentially positioned at thecontainer fill station 40 to define a containerfirst loading section 68. An incomplete container such asincomplete container 14 a received in thecontainer fill station 40 abuts against asecond stop member 70 which is fixed in position and coaxially aligned withstop member 52 until theincomplete container 14 a contacts afixed stop member 72 at the position ofincomplete container 14 a shown. - After the container is filled in
container fill station 40, a direction of rotation of each of theconveyor rollers 60 of containerfirst loading section 68 andcontainer redirecting section 64 can be reversed to move the now complete container in the complete container discharge direction “F” until the complete container contacts a raisedthird stop device 74.Third stop device 74 is positioned betweenconveyor rollers second stop device 66,third stop device 74 can be raised or lowered to be above or below the elevation ofconveyor rollers 60 incontainer redirecting section 64. For example,third stop device 74 is positioned in the lowered position to permitincomplete container 14 a to reach thecontainer fill station 40. Once the nowcomplete container 22 contactsthird stop device 74, athird pusher member 76, which is coaxially aligned with each ofstop member 52 andsecond stop member 70 in a first operating position, is moved from the position shown asthird pusher member 76 to the position shown asthird pusher member 76′. - At the position shown as
third pusher member 76′, thecomplete container 22 or anotherincomplete container 14 is moved onto infeed/discharge section 48 in the container transport direction “C”.Third pusher member 76 thereafter returns to the position shown which is coaxially aligned withstop member 52 until a next sequence of operations occurs. Each of theloading stations 44 includes astation positioning device 78 represented by the variousstation positioning devices station positioning device 78 includes a first pusher/alignment member 80 and an oppositely positioned second pusher/alignment member 82. The first and second pusher/alignment members incomplete container 14 into one of the loadingstations 44. Each of thestation positioning devices 78 therefore includes arod-less cylinder 84 having a slidably displacedcarriage member 86 with the first and second pusher/alignment members carriage member 86 is movable from the position shown ascarriage member 86 to the position shown ascarriage member 86′ by powered operation such as by using a pressurized air system for displacement. - If the
incomplete container 14 is to be moved from infeed/discharge section 48 intoloading station 44 a, for example, afirst stop device 88, which is similar to second andthird stop devices incomplete container 14, therefore positioning theincomplete container 14 between first and second pusher/alignment members First stop device 88 is actuated using astop actuator 90 which is connected to structure supportingloading station 12.First stop device 88 is coaxially aligned with analignment guide 92, commonly provided in each of the loadingstations 44. Theincomplete container 14 moving intoloading station 44 a therefore slides with respect tofirst stop device 88 until it slidablycontacts alignment guide 92, which provides a consistent location for any of theincomplete containers 14 received in loadingstation 44 a or any of the other loading stations. - The first and second pusher/
alignment members loading station 44 c) as the container is filled. Once the one or more items required for the container are loaded creating acomplete container 22, the carriage member 86 (shown ascarriage member 86′ inloading station 44 c) is commanded to move in the complete container discharge direction “F”, whereby second pusher/alignment member 82′ provides a motive force for displacing the nowcomplete container 22 from theloading station 44 c and back onto infeed/discharge section 48 for discharge from loadingstation 12. In feed/discharge section 48 further includes an individual stop device (such as fourth, fifth,sixth stop devices stations incomplete container 14 traveling in the container transport direction “C” on infeed/discharge section 48 for subsequent delivery into one of thevarious loading stations 44. Each of the stop devices operate in a similar manner using a similar stop actuator, such asstop actuator 90. - Referring to
FIG. 4 ,loading station 12 can further include a plurality of support stanchions 100 (such assupport stanchions support surface 102, such as a substantially planar floor surface.Container entry portion 38 further includes a secondstop device actuator 104 operable to movesecond stop device 66 upwardly or downwardly as previously described herein. A plurality of substantially equally spaced, partially fixedconveyor rollers 106 are arranged in parallel and rotatably connected to aroller support structure 107.Roller support structure 107 is subsequently connected to asupport beam 108, which is connected to and supported by the various support stanchions 100. The height of theconveyor rollers 106 with respect to supportsurface 102 can be varied, if desired, by using adjustable members in support stanchions 100 to accommodate a plurality of container sizes. - Referring to
FIG. 5 , each of theconveyor rollers 60 ofcontainer entry portion 38 are arranged in parallel with each other such that aplanar surface 110, defined by theupper surface 112 of each of theconveyor rollers 60, is oriented coplanar to the sameplanar surface 110 defined by theupper surfaces 114 of each of theconveyor rollers 106. As shown,second stop device 66 can be lowered to a position belowplanar surface 110 to permit free transportation of the containers and can be raised to the position shown atsecond stop device 66′, positioned above theplanar surface 110, by actuation of secondstop device actuator 104. Thefirst stop device 88 and similar stop devices are movable by anextendable shaft 116 connected to astop device arm 118.Stop actuator 90, for example, displaces theextendable shaft 116, thereby moving bothstop device arm 118 andfirst stop device 88 either upwardly or downwardly. Each of the stop devices, such asfirst stop device 88, is positioned between successive ones ofconveyor rollers 106, such as betweenconveyor rollers alignment member 82 a, includes apusher extension rod 120 connected to a pusher actuator, such aspusher actuator 122.Pusher actuator 122 is connected to supportbeam 108. Thepusher extension rod 120, similar to stopdevice arm 118, is positioned between successive ones of theconveyor rollers 106, such as betweenconveyor rollers - Referring to
FIG. 6 , each of theconveyor rollers 106 is divisible into a fixedroller 124 and apowered roller 126.Fixed roller 124 is not axially rotatable and is therefore fixed in position to receive and temporarily support the individual incomplete or complete containers. A bearingassembly 128 separates fixedroller 124 frompowered roller 126, permittingpowered roller 126 to axially rotate. Adrive belt 130 or any similar drive or motive device is provided for each of the individual poweredrollers 126, which if in belt form is rotatably connected to adrive shaft 131 powered by a motor (not shown). Aguide member 132 can be provided at loadingstation 12, which can provide additional support for taller ones of the containers (i.e.,container 14 c).Guide member 132 is supported by a plurality of guidemember support arms 134, which can be connected toroller support structure 107. According to additional embodiments, fixedrollers 124 can also be replaced by any fixed or stationary surface. - Referring to
FIG. 7 and again toFIG. 3 ,container receiving station 18 includes a plurality of poweredrollers 135 directingincomplete containers 14 towardstop member 52. Similar to poweredrollers 126 shown and described with respect toFIG. 6 , each of theconveyor rollers 60 ofcontainer entry portion 38 is similarly rotated using adrive belt 136 connected to apulley 138, which is rotated by adrive shaft 140. As previously noted, after the container is completed incontainer fill station 40, a direction of rotation R1 of each of theconveyor rollers 60 used to direct the container in the container entry direction “E” onto containerfirst loading section 68 andcontainer redirection section 64 can be reversed to a direction of rotation R2 to move the now complete container in the complete container discharge direction “F” until the complete container contacts raisedthird stop device 74.Second stop device 66 is lowered during this event. The one ormore drive belts 136 is/are received in adrive slot 142 created in each of theconveyor rollers 60.Drive slot 142 is provided to maintain alignment ofpulley 138 and also to keep eachdrive belt 136 positioned belowupper surface 112, thereby not interfering with the passage of the containers with respect toupper surface 112. Acarriage member 143 is slidably disposed on incomplete containerrod-less cylinder 54 to slidably displacepusher member 56. A thirdstop device actuator 144 is provided to upwardly and downwardly movethird stop device 74. Apusher member actuator 145 connected to apusher member rod 147 is actuated to movethird pusher member 76. Anactuator controller 146 can be provided to control the flow of, for example, pressurized air to any of thestop actuators 90, secondstop device actuator 104,pusher actuators 122, stopdevice actuator 144, and/orpusher member actuator 145. - A
system controller 148 is provided, which communicates with each of the drive motors, stop actuators, and pusher actuators, to direct operation of these items in the sequential order necessary for moving the containers about loadingstation 12.System controller 148 therefore may contain hardware and electronic controls directed to the sequential operation of loadingstation 12, including operation of the various motors for driving the conveyor rollers and code reading devices. According to several embodiments, a programmable logic device and/or one or more computers, herein collectively defined as acomputer 150 is also provided withdelivery system 10, which can be incorporated withinsystem controller 148.Computer 150 can be programmed with or connected to other computers or databases to request information, such as the type and quantity of components to be inserted into each container, the station or stations at which individual containers are directed to, the timing of the entry and exit of the various containers from the system, the timing of operation of the various stop devices and pusher members, and can receive and implement commands for operation ofsystem controller 148 from a programmer and/or an operator.Loading station 12 can further include asupport frame 152 adapted to support the features ofcontainer entry portion 38. - Referring to
FIG. 8 , the plurality ofconveyor rollers 60, each having adrive slot 154, is rotatably disposed with respect to first andsecond mount brackets second mount plates third pusher member 76 connected to acarriage member 159 which is slidably disposed onrod-less cylinder 161. In addition to first andsecond mount brackets rod-less cylinder 161 can further be fixedly connected to the first andsecond mount plates Rod-less cylinder 161 includes aslide track 162 which provides for sliding motion ofcarriage member 159 and therebythird pusher member 76 between the first andsecond mount plates Third pusher member 76 can slide between the position shown asthird pusher member 76 to the position shown asthird pusher member 76′ in each of the container transport direction “C” and pusher return direction “H”. - Referring to
FIG. 9 ,delivery system 10 includes acontainer reading station 164 which includes containercode reading device 20 which is capable of reading aautomatic identification 166 attached to each of theincomplete containers 14 as they arrive atcontainer reading station 164. This data indicating the individual type ofincomplete container 14 and its entrance into the system is then transmitted tocomputer 150, shown and described in reference toFIG. 7 . A complete containercode reading device 168 can also be provided at a discharge end of loadingstation 12 which is operable to read anautomatic identification 166 such as a bar code or RF tag, RFID reader, or similar means of container identification from the nowcomplete container 22 as it leaves loadingstation 12. This information is also forwarded tocomputer 150 which confirms thatcomplete container 22 has exited from loadingstation 12. - Each of the first, second, and
third carousels motorized track 170 about which a plurality ofcarousel bins 172 are connected and rotate with respect to a carousel rotational direction “J” which can be either a clockwise or counterclockwise direction of rotation.Delivery system 10 is provided with the information relating theindividual components 175 which are provided in thecarousel bins 172 with this information further programmed intocomputer 150.Delivery system 10 is, therefore, programmed to provide theindividual carousel bins 172 necessary to fill individual ones of thecontainers 14 with at least oneitem 175 by an operator positioned within afill area 174 by positioning thevarious carousel bins 172 at individual ones of the first, second, orthird pick locations area 174. - Referring to
FIG. 10 , a put tolight system 176 provides a plurality of pushbutton display units 178, shown for example as pushbutton display units stations button display units 178 is connected to a mountingchannel 180 which can be connected to structure of loadingstation 12. Each of the pushbutton display units 178 includes a data read outscreen 182, which provides for the operator component information such as an identification number, and a quantity of a unique component required to fill/complete an individual container or two or more containers, and other information related to completing the container, such asloading station 44 a. A plurality ofdata entry buttons 184 is provided with each of the pushbutton display units 178 for the operator to enter data, such as the quantify of the part or parts actually loaded into the container. Included withdata entry buttons 184 is a containercomplete button 184 a, which the operator presses to indicate todelivery system 10 that the container positioned at the appropriate loading station has been completed. This information presented by and input into pushbutton display unit 178 is also transmitted tocomputer 150, shown and described with reference toFIG. 7 . - Referring to
FIG. 11 , operation of loadingstation 12 can be as follows. Anincomplete container 14 received atstop member 52 is pushed by operation offirst pusher member 56 in the second feed direction “B” ontoconveyor rollers 60 ofcontainer entry portion 38. If theincomplete container 14 is to be transferred to container fillstation 40, both second andthird stop devices conveyor rollers 60. Conveyor rollers are rotated to moveincomplete container 14 in the second feed direction “B” untilincomplete container 14 contacts fixedstop member 72, at which time the container is available for filling. Once filled, the direction of rotation ofconveyor rollers 60 is reversed to move the now complete container (re-identified as a complete container 22) in the complete container discharge direction “F”.Second stop device 66 is kept at the lowered position andthird stop device 74 is raised to stopcomplete container 22 such that subsequent operation ofpusher member 76 in the container transport direction “C” pushes the container onto power rotatedrollers 126 for subsequent discharge from loadingstation 12. - For other
incomplete containers 14 moving ontoconveyor rollers 60,third stop device 74 is positioned at the lowered position andsecond stop device 66 is raised to stop the container(s) for subsequent movement bypusher member 76 onto power rotatedrollers 126. The incomplete container is moved in the container transport direction “C” on power rotatedrollers 126 until reaching thepredetermined loading station 44. To stop the incomplete container at the desired loading station, one of the first, fourth, fifth, or later stopdevices alignment members 80, 82 (or 80′, 82′ or the like) is moved in the container entry direction “E” until the incomplete container is positioned on fixedrollers 124 of infeed/discharge section 48, where the container is loaded. The operator receives the appropriate loading information on thepushbutton display unit 178 at the loading station, and notifies the system when all the tasks (fill items) related to the container are complete (or if all the available parts in the carousel have been loaded) by data entry intopushbutton display unit 178. This complete signal notifies the delivery system thatcomplete container 22 should be moved in the complete container discharge direction “F” by actuation of first and second pusher/alignment members 80, 82 (or 80′, 82′ or the like) until the complete container is moved onto power rotatedrollers 126 of load/discharge section 46. - Once the
complete container 22 is positioned on power rotatedrollers 126, the appropriate ones of first, fourth, fifth, and later stopdevices discharge section 46 in the container transport direction “C”. The incomplete or complete status of each of the containers on loadingstation 12 is tracked bydelivery system 10, as well as the position of each container. Additional sensor devices such as UPC code readers or similar identification devices noted herein can be used at each loading station and/or at each position of the first, fourth, fifth, and later stopdevices - An
automatic delivery system 10 of the present disclosure can therefore includeconveyor 45 havingrollers 106 arranged in parallel with each other defining a common spacing “S2” between any sequential ones of therollers 106. Spacing “S2” can be equal to or different from spacing “S1” used forrollers 60 ofcontainer entry portion 38. Theconveyor rollers 106 are divisible into at least two groups defined as load/discharge section 46 and infeed/discharge section 48, each of the at least two groups including aloading station 44 at one end of theconveyor rollers 106. Each of the at least two groups having astation positioning device 78 including at least oneextension rod 120 extending through and displaceable within the spacing “S2” between two sequential ones (for example 106 c, 106 d) of therollers 106, thestation positioning device 78 operating to displace acontainer 14 received on therollers 106 into and out of theloading station 44. - According to other embodiments,
automatic delivery system 10 includesconveyor 45 having first poweredrollers 126 arranged in parallel with each other defining a spacing “S2” between sequential ones of the poweredrollers 126. Secondfixed rollers 124 are each connected to and coaxially aligned with individual ones of the poweredrollers 126 and sequentially separated by the spacing “S2” of the first poweredrollers 126. The secondfixed rollers 124 are divisible into at least two groups, each of the at least two groups defining aloading station 44 such asloading stations loading stations 44 have astation positioning device 78 including at least oneextension rod 120 extending through and horizontally displaceable within the spacing “S2” between two sequential ones of the powered first and fixed second rollers (for example betweenconveyor rollers station positioning device 78 operating to displace acontainer 14 received on the first poweredrollers 126 into and out of the loading station (44 a, 44 b, 44 c, and the like). - Referring again to
FIGS. 3 and 6 , according to further embodiments, therollers 60 ofcontainer entry portion 38 and the fixedrollers 124 can be replaced with individual fixed members or by fixed surfaces having access for operation of the various pusher members and stop devices created therethrough. Other types of conveyors such as fixed or belt conveyors can also be used in place ofrollers 60 ofcontainer entry portion 38 and the fixedrollers 124. - According to still other embodiments, a stop device (such as first stop device 88) is positioned between and extended upwardly and retracted downwardly through the spacing “S2” between second sequential ones (106 a, 106 b) of the first powered
rollers 126 and secondfixed rollers 124. The stop device (such as first stop device 88) is extended upwardly to stop thecontainer 14 for subsequent displacement by thestation positioning device 78, and is extended downwardly to permit free passage of thecontainer 14 on the first poweredrollers 126. - With continuing reference to the Figures,
containers 14 are scanned automatically when entering the Continuous BatchOrder Processing System 10. As eachcontainer 14 is scanned,computer 150 assigns a loading station destination and then controls and tracks the routing of thatcontainer 14 to the assigned station. Once thecontainer 14 reaches the assigned loading station,computer 150 retrieves picking data (i.e., item stock numbers and quantities) from a database or other computer having this data, calculates optimum first, second, and/orthird carousel third carousels container loading stations 44 are empty,incomplete containers 14 will be automatically inducted, scanned, and routed to their assigned locations until allstations 44 are occupied or there are no additional containers to induct. - As pick information is sent to the
carousels computer 150 monitors the rotation ofcarousels location computer 150 illuminates a pick light display adjacent to the pick position identifying the location and quantity of product (item) to pick atpick location carousel container 14 at theloading stations 44 will display the quantity of product (item or items) to put into eachadjacent container 14. Once the item (product or products) have been picked and placed in eachcontainer 14 indicated bycomputer 150, the operator depresses the task complete button at the appropriatecontainer loading station 44pushbutton display unit 178 to signal completion of the put (task) for the product picked. - After all
containers 14 requiring a put from that location (i.e., first, second, orthird pick locations complete button 184 a,computer 150 will internally flag that task as complete and send the next required pick location to the carousel controller. If selected in an operational configuration, an operator will be requested to verify a carousel stock location as being empty-while-picking if the expected result of completing the pick fully depletes stock at thecarousel picking location computer 150 will display ‘DONE’ on the put light at thepushbutton display unit 178 of theparticular loading station 44, automatically transfer the completedcontainer 22 back to the infeed/discharge conveyor 48 and automatically induct the nextincomplete container 14 into the nowempty loading station 44. As eachincomplete container 14 reaches theload location 44, thecomputer 150 recalculates required picks and optimum carousel rotational sequence for all containers in the batch. - The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the invention, and all such modifications are intended to be included within the scope of the invention.
Claims (22)
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
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US12/766,620 US8774961B2 (en) | 2010-04-23 | 2010-04-23 | Automatic delivery system for continuous batch order processing |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
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US12/766,620 US8774961B2 (en) | 2010-04-23 | 2010-04-23 | Automatic delivery system for continuous batch order processing |
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US20110259715A1 true US20110259715A1 (en) | 2011-10-27 |
US8774961B2 US8774961B2 (en) | 2014-07-08 |
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